Easy-open peel pouch

ABSTRACT

A package for containing and dispensing a product is disclosed. The package has a first layer, a second layer, and at least a first seal zone where the first layer is joined to the second layer by a peelable seal. The first seal zone has an inner perimeter that defines an unsealed pouch area for containing the sheet product. A tab cut is defined in the first layer that divides the package into a package zone and a tab zone. A method and relevant manufacturing equipment are also disclosed.

FIELD OF THE INVENTION

The technology described herein generally relates to a package having apouch area. More particularly the technology described herein relates toa package where layers are peeled apart to access a pouch area.

BACKGROUND

Many different types of packages are made with two or more layers ofmaterial that are sealed together to form a pouch for containing aproduct, and then can be peeled apart to access the product. In someareas of technology, it is desirable to have access to products that aresterile for their eventual use. This is a common issue in the medicalfield, for example, where it is desirable that products used in medicalprocedures remain sterile over transport to and from manufacturingfacilities, medical facilities, and the like, in addition to whilestored in those facilities. In some package designs, it is difficult toseparate the layers of package in order to grasp the layers and peelthem apart. Static electricity may play a role in making the layersdifficult to separate. A cutting process for cutting the outer packageperimeter may fuse the layers together at their outer perimeters to somedegree, which can make the layers difficult to separate.

Some packages are made with a notch that enables the user to tear alllayers of the package starting at the notch, in order to gain access toat least part of the pouch area containing the product. However, tearingall layers across the pouch area can cause damage to fragile contents.Also, tearing all layers across one side of a pouch area can still makeit difficult to remove the contents in some situations.

Time and frustration become issues in situations where a packagerequires the manual separation of thin layers to open especially whenthe user is wearing gloves or addressing an urgent medical need.

SUMMARY OF THE INVENTION

In one embodiment, a package for containing and dispensing a productincludes a first layer, a second layer, and at least a first seal zonewhere the first layer is joined to the second layer by a peelable seal,the first seal zone having an inner perimeter that defines an unsealedpouch area for containing the product and an outer perimeter. Thepackage further includes an unsealed header zone adjacent to the outerperimeter of the first seal zone, wherein the first layer is not joinedto the second layer in the unsealed header zone. The package alsoincludes a first tab cut in the first layer within the unsealed headerzone, wherein the first tab cut divides the package into a package zoneand a first tab zone.

In one embodiment, a method of forming a package for containing anddispensing a product includes providing a first layer web and a secondlayer web and placing a product on at least one pouch area of one of thefirst and second layer webs. The method also includes forming a combinedweb by sealing the first layer web to the second layer web at least at afirst seal zone so that the first layer is joined to the second layer bya peelable seal surrounding the at least one pouch area, and leaving anunsealed header zone adjacent to an outer perimeter of the first sealzone where the first layer web is not sealed to the second layer web.The method further includes cutting at least one individual packagearound an outer package perimeter to separate the individual packagefrom the combined web, wherein cutting further comprises cutting onlythe first layer of the package at a first tab cut location within theunsealed header zone to define a first tab zone in the package.

In one embodiment, a device for forming a package for containing anddispensing a sheet product includes a heat seal plate for joining afirst layer web and a second layer web with a heat seal at first sealzones to form a combined web, wherein the seal plate defines at leastone first seal zone having an inner perimeter and an outer perimeter.The device also includes a cutting die for cutting the combined web toform at least one individual package and for cutting through only thefirst layer at a tab cut location, where the first tab cut location isnot within any of the first seal zones on the combined web.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention may be more completely understood and appreciated inconsideration of the following detailed description of variousembodiments of the invention in connection with the accompanyingdrawings.

FIG. 1 depicts a front view of a package consistent with the technologydisclosed herein.

FIG. 2 depicts a side view of the package of FIG. 1 with a tab portionand part of one layer bent away from the remainder of the package.

FIG. 3 depicts a front view of another embodiment of a packageconsistent with the technology disclosed herein.

FIG. 4 depicts a front view of yet another embodiment of a packageconsistent with the technology disclosed herein.

FIG. 5 depicts a front view of another embodiment of a packageconsistent with the technology disclosed herein.

FIG. 6 depicts a front view of another embodiment of a packageconsistent with the technology disclosed herein.

FIG. 7 depicts a front view of another embodiment of a packageconsistent with the technology disclosed herein.

FIG. 8 depicts a flow chart consistent with a method described herein.

FIG. 9 depicts an example web consistent with the technology disclosedherein.

FIG. 10 is a schematic drawing of one embodiment of package-makingequipment disclosed herein.

DETAILED DESCRIPTION

The package described herein is generally configured to contain anddispense a product. The product can be medical in nature and can berelated to surgical needs, pharmaceutical needs, medical emergencyresponder needs, and the like. In some embodiments the product is awound dressing, a medical care product, a medical device, and the like.In some embodiments the product is a sheet product such as a solublefilm that can be relevant to edible applications, oral applications,skin care applications, cosmetic applications, and the like. A sheetproduct generally is very thin and has width and length dimensions thatare significantly larger than its thickness dimension, such as where thewidth and length are at least ten times the thickness dimension, orwhere the width and length are at least one-hundred times the thicknessdimension. Sheet products sometimes have parallel sides. In some cases,a wound dressing is a sheet product.

FIG. 1 depicts a front view of a package consistent with the technologydisclosed herein. FIG. 2 depicts a side view of the package of FIG. 1where a tab zone 154 and part of one layer 170 is bent away from theremainder of the package 100. The package 100 contains a product 10 andgenerally has a first layer 160 and a second layer 170. In FIG. 1, theproduct 10 is shown in dashed lines beneath the first layer 160. Theproduct 10 may be visible through a transparent layer or layers or maynot be visible within the package 100. The package 100 defines a firstseal zone 130, illustrated with cross-hatching, where the first layer160 is joined to the second layer 170 by a peelable seal 180. The firstseal zone 130 has an inner perimeter 110 and an outer perimeter 140. Inthe embodiment of FIG. 1, the inner and outer perimeters 110, 140 bothhave a substantially rectangular shape, with the inner perimeter 110having rounded corners. In other embodiments, these perimeters havedifferent shapes, such as with or without rounded corners, with orwithout square corners, rectangles, ovals, circles, squares and others.An unsealed pouch area 120 is defined by the inner perimeter 110 of thefirst seal zone 130 and contains the product 10. A tab cut 150 isdefined in the first layer 160 that divides the package into a packagezone 156 and a tab zone 154.

In the current embodiment, the package 100 has an outer perimeter 157that is rectangular and the tab zone 154 is defined in the corner of thepackage 100. In some embodiments it can be desirable to have a packagein a different shape with a tab zone in a different location, however.Some alternatives will be discussed herein. In one embodiment, thepackage shape is circular, oval or tombstone shaped with a rectangularbase portion and a curved top portion.

The package includes an unsealed header area 122 where the first layer160 is unattached to the second layer 170. In the embodiment of FIG. 1,the outer perimeter 140 of the first seal zone 130 defines one side ofthe unsealed header area 122 and the outer perimeter 157 of the packagedefines other sides of the unsealed header area 122. In the unsealedheader area 122, a user can separate the two layers and can grasp thefirst layer 160 and the second layer 170 to peel them apart to accessthe product 10. However, sometimes static electricity may play a role inmaking the layers difficult to separate. Also, the cutting process usedto cut the outer package perimeter may fuse the layers together at theirouter perimeters to some degree, which can make the layers difficult toseparate. Also, if a user is wearing gloves, under time pressure orboth, a delay in separating the two layers to peel them apart could beespecially frustrating.

The tab cut 150 and tab zone 154 are configured to facilitate theseparation of the first layer 160 from the second layer 170. The tab cut150 through the first layer 160 in the unsealed header area 122physically decouples the portion of the first layer 160 within the tabzone 154 from the portion of the first layer 160 outside of the tab zone154 (in the package zone 156). As a result, when the user bends thepackage in the tab zone 154, the first layer 160 separates from thesecond layer 170 at the tab cut 150, so that the user can easily graspthe tab zone 154 of the package, easily grasp the first layer 160 in theunsealed header and then can pull the second layer 170 away from thefirst layer 160.

In some embodiments, such as the embodiment of FIG. 1, a second sealzone 132 is present in the tab zone 154 where the first layer 160 isjoined to the second layer 170. The second seal zone 132 physicallycouples the portion of the first layer 160 within in the tab zone 154 tothe second layer 170. As such, when the user grasps the tab zone 154,the user is grasping the sealed first and second layers in the tab zone154. The second seal zone 132 is separated from the first seal zone 130by the unsealed header area 122. Second seal zone boundary 112 defines aboundary of the second seal zone 132 and divides the second seal zone132 from the unsealed header area 122.

In some embodiments, such as the embodiment shown in FIG. 7 which willbe further described herein, the first layer is not joined to the secondlayer by a second seal zone. In these embodiments, a portion of thefirst layer in the tab zone is separated from the rest of the package bythe tab cut and is no longer connected to the package. In theseembodiments, the first layer of the package within the tab zone isremoved, exposing the second layer in the tab zone. The first layer inthe tab zone can be removed through use of a vacuum in one embodiment ora blower in another embodiment, although other methods can certainly beused as well. Each of the embodiments illustrated in FIGS. 1-6 areillustrated to include a second and sometimes a third seal zone butcould also be provided without the additional seal zones. Likewise, theembodiment of FIG. 7 could be provided with the second seal zone. Wherean embodiment includes a second seal zone, the step of removing the tabzone portion of the first layer is not necessary, since the tab zoneportion of the first layer is adhered to the tab zone portion of thesecond layer. In this situation, the tab zone of the package includesthe first and second layers adhered together, and the tab zone istherefore thicker than either of the two layers separately.

Layer Material Options

The first layer 160 and the second layer 170 can include a variety ofmaterials and combinations of materials that are generally known in theart, such as a polyester film, spunbonded olefin, DuPont TYVEK® brandspunbonded olefin, linear low density polyethylene with polybutylene,biaxially oriented polyester film, polypropylene film, high densitypolyethylene film, BAREX® acrylonitrile co-polymer film available fromBP Chemicals, Inc., cast polyethylene terephthalate (PET) orpolyethylene terephthalate glycol (PETG) film, metal foil, aluminumfoil, poly-vinylidene dichloride (PVDC) film, co-extruded filmscontaining ethylene vinyl alcohol polymer (EVOH), polyvinyl alcohol(PVA) film, polyamide film, vinyl film, or composite laminations orcoatings that contain the same. In a variety of embodiments, the firstlayer 160 and the second layer 170 are heat sealable. In someembodiments, only one of the first layer 160 and second layer 170 isheat sealable, and the other is a compatible material to create a peelseal. In one embodiment, each of the first and second layers includes apolyester layer, such as a DuPont TYVEK® brand spunbonded olefin, a tielayer and a sealant layer. In one embodiment, the polyester film, tielayer and sealant layer are coextruded or laminated to form a singlefilm. One example of an appropriate sealant layer is linear low densitypolyethylene with polybutylene, which is activated by heat to bond tothe other layer. In some embodiments, the layers are joined by methodsother than heat sealing. For example, the layers may be joined byultrasonic welding in some embodiments. In some embodiments, the layersmay be joined by more than one method, such as both heat sealing andultrasonic welding.

In a variety of embodiments, the first layer 160 and the second layer170 are substantially non-permeable. In a variety of embodiments, thefirst layer 160 and the second layer 170 are substantially permeable.For example, a layer that includes a metal foil layer will besubstantially non-permeable, while a layer that includes a DuPont TYVEK®brand spunbonded olefin will be permeable. In a variety of embodiments,the first layer 160 and the second layer 170 are substantially flexible,although in some embodiments one of the first layer 160 or the secondlayer 170 or both are substantially rigid. In some embodiments, one orboth of the layers is transparent so that the product 10 is visiblethrough the transparent layer. Alternative terms that can be used todescribe the first layer 160 and the second layer 170 include film,sheet, web, and the like.

The first layer 160 is generally coextensive with the second layer 170so that the two layers share a common outer perimeter. As mentionedabove, the first layer 160 and second layer 170 are joined with apeelable seal 180. Generally, the peelable seal 180 is a hermetic bondbetween the contacting surfaces of the first layer 160 and second layer170. The peelable seal 180 can be formed by any appropriate method knownin the art. In a variety of embodiments, peelable seal 180 is a heatseal or melt bonded relationship caused by the application of heat andpressure. In an alternate embodiment, peelable seal 180 is formed with asuitable adhesive applied to at least one of the contacting surfaces ofthe first layer 160 and second layer 170. In at least one embodiment,the peelable seal 180 is re-sealable, thereby allowing a user to reclosethe package 100.

In general the peelable seal 180 is configured to have strengthconducive to allowing a user to peel the first layer 160 and the secondlayer 170 apart without the use of tools, to access the product 10 therebetween. In one embodiment, the peelable seal strength is in the rangeof 1.25 to 2 pounds per linear inch of seal when pulled apart at 180degrees at 12 inches per minute travel rate according to testingprocedure TAPPI T-494 as published by the Technical Association of thePulp and Paper Industry. In some embodiments the peelable seal strengthis in the range of 1.0 to 2.5 pounds per linear inch of seal. In avariety of embodiments the peelable seal has strength in the range of0.25 to 3.5 pounds per linear inch of seal.

Options for the Second Seal Zone

Similar to the first seal zone 130, the second seal zone 132 can beformed by any appropriate method known in the art. The second seal zone132 can be formed in an identical way as the first seal zone 130, asimilar way as the first seal zone 130 or in a different way. In oneembodiment, the second seal zone 132 and the first seal zone 130 areformed through heat sealing the first layer 160 to the second layer 170.

Description of Embodiments of FIGS. 3-7

Those having skill in the art will appreciate the variety ofconfigurations consistent with the technology disclosed herein. FIGS.3-7 show five different embodiments where the tab zone or tab zones andthe additional seal area or seal areas are configured in different ways.FIG. 3 depicts a front view of package embodiment 200 which includes afirst layer and a second layer (not visible from the front view angle ofFIG. 3) and defines a first seal zone 230 with an inner perimeter 210and an outer perimeter 240. An unsealed pouch area 220 is defined by theinner perimeter 210 and contains a product 10. In this embodiment,however, a first tab cut 250 defines a first tab zone 252 and a secondtab cut 254 defines a second tab zone 256. A second seal zone 232 in thefirst tab zone 252 and a third seal zone 234 in the second tab zone 256are separated from the first seal zone by an unsealed header area 222.In the embodiment of FIG. 3, there are two tab zones 252 and 256 whichboth provide a location for the user to grasp when opening the packagewhich will easily separate from the remainder of the unsealed headerarea so that the two layers of the package can be easily peeled apart.Second seal zone boundary 212 defines a boundary of the second seal zone232 and divides the second seal zone 232 from the unsealed header area222. The third seal zone 234 also has a boundary 214 that divides thethird seal zone 234 from the unsealed header area 222.

Those having skill in the art will appreciate that a tab cut can have avariety of configurations and locations. In some embodiments the tab cutis a straight line. In other embodiments the tab cut is curved. In atleast one embodiment the tab cut can include intersecting sides. In someembodiments depicted herein, the tab cut is near a corner while in someembodiments the tab cut is near a center of one side of the package. Inother embodiments, the tab cut is located at different positions along aside of the package. FIG. 4 depicts a front view of yet anotherembodiment of a package consistent with the technology disclosed herein.In this embodiment the package 300 similarly has a first layer and asecond layer (not visible from the front view of FIG. 4) and defines afirst seal zone 330 with an inner perimeter 310 and an outer perimeter340. An unsealed pouch area 320 is defined by the inner perimeter 310and contains the product 10. A tab cut 350 defined in the first layerdefines a tab zone 352 that is distinguished from a package zone 354. Asecond seal zone 332 is in the tab zone 352 and is separated from thefirst seal zone 330 by an unsealed header area 322. A boundary 312 ofthe second seal zone 332 separates the second seal zone 332 from theunsealed header area 322. In this embodiment the tab cut 350 is curved.In this embodiment the tab cut 350 intersects the edges of the packageperimeter 357 at substantially a right angle. Positioning cutting edgesat right angles on the die can be desirable since material can sometimesaccumulate at acute angles between cutting structures.

The first seal zone and the second seal zone can have a variety ofconfigurations. In the embodiments disclosed herein, the outer perimeterof the first seal zone has a generally rectangular shape and extends tothe edges of the package on three sides. The inner perimeter is alsogenerally rectangular in shape, where the rectangle has curved corners.Many other shapes will be conducive to the technology disclosed herein.For example, the package perimeter and the first seal area could be ovalor circular. The second seal zone (and third seal zones, whereapplicable) can also have a variety of shapes and placements. In theembodiments disclosed herein, the second seal zone extends to at leastone edge of the package, although there are a variety of instances wherethe second seal zone does not extend to an edge of the package. In avariety of embodiments the second seal zone is triangular in shape. Insome embodiments the second seal zone is rectangular in shape. In yetother embodiments the second seal zone is circular in shape. Where thesecond seal zone is formed through heat sealing, a shape can be definedin a die that creates the second seal zone.

FIG. 5 depicts a front view of another embodiment of a packageconsistent with the technology disclosed herein. In this embodiment thepackage 400 has a first layer and a second layer (not visible from thefront view of FIG. 5) and defines a first seal zone 430 with an innerperimeter 410 and an outer perimeter 440. An unsealed pouch area 420 isdefined by the inner perimeter 410, where the unsealed pouch area 420 isconfigured to receive a product 10. A tab cut 450 defined in the firstlayer defines a tab zone 452 that is distinguished from a package zone454. The package zone includes the remainder of the package excludingthe tab zone. A second seal zone 432 is in the tab zone 452 and isseparated from the first seal zone 430 by an unsealed header area 422.In this embodiment the tab cut 450 is also curved and intersects with anedge of the package 400. The tab cut 450 is located at the center of theedge of the unsealed header area 422. The second seal zone 432 issubstantially rectangular and is within the tab zone 452. A boundary 412of the second seal zone 432 separates the second seal zone 432 from theunsealed header area 422. In other embodiments, the tab cut 450 islocated at other non-central locations along the edge of the unsealedheader area 422.

FIG. 6 depicts a front view of another embodiment of a packageconsistent with the technology disclosed herein. In this embodiment thepackage 500 has a first layer and a second layer (not visible from thefront view of FIG. 6) and defines a first seal zone 530 with an innerperimeter 510 and an outer perimeter 540. An unsealed pouch area 520 isdefined by the inner perimeter 510 and contains a product 10. In thisembodiment, a first tab cut 550 and a second tab cut 554 are present inonly the first layer, are curved and are located at the outer perimetercorners of the package in the unsealed header area 522. The first tabcut 550 defines a boundary of a first tab zone 552 while the second tabcut 554 defines a boundary of a second tab zone 556. The first tab zone552 and the second tab zone 556 are distinguished from the package zone558. A second seal zone 532 in the first tab zone 552 and a third sealzone 534 in the second tab zone 556 are separated from the first sealzone 530 by an unsealed header area 522. The second seal zone 532 andthird seal zone 534 are rectangular and border the corners of the outerperimeter 557 of the package 500. The second and third seal zones 532,534 could be formed in different shapes and located at other locations.For example, the second and third seal zone could be circular or oval,and could be located at a location offset from the corners. A boundary512 of the second seal zone 532 separates the second seal zone 532 fromthe unsealed header area 522. A boundary 513 of the third seal zone 534separates the third seal zone 534 from the unsealed header area 522.

FIG. 7 depicts a front view of another embodiment of a packageconsistent with the technology disclosed herein. In this embodiment thepackage 600 has a first layer and a second layer and defines a firstseal zone 630 with an inner perimeter 610 and an outer perimeter 640. Anunsealed pouch area 620 is defined by the inner perimeter 610 andcontains a product 10. A tab cut 650 defines a tab zone 652, and theremainder of the package is referred to as the package zone 654. The tabcut 650, is approximately half-circle shaped, is curved and intersectsthe perimeter 657 of the package at substantially a right angle. The tabcut 650 is located at the center of the outer perimeter edge of theunsealed header area 622. In this embodiment, the first layer of thepackage 600 within the tab zone 652 is removed, exposing the secondlayer 670 in the tab zone 652. The first layer in the tab zone 652 canbe removed through use of a vacuum in one embodiment or a blower inanother embodiment, although other methods can certainly be used aswell.

In another embodiment, the tab cut is a chevron shape located at thecenter of the outer perimeter edge of the unsealed header area. Thisembodiment can have a second seal area within the chevron or may lack asecond seal area.

FIG. 8 depicts a flow chart consistent with one method of manufacturinga package consistent with the technology disclosed herein. Generally, atleast two webs are provided 20, product is placed 30 on one web, thewebs are sealed 40 to enclose the product within an unsealed area, andthen the web is cut 50 into packages and the tab cut is made. FIG. 9depicts an example combined web 1000 consistent with the methodassociated with FIG. 8 prior to cutting 50. The packages formed fromthese components can be for containing and dispensing a product.

The step of providing webs 20 generally encompasses providing a firstlayer web and a second layer web, although additional webs can beprovided also. The first layer web and second layer web can be a varietyof different materials, as described above with regard to FIGS. 1 and 2.Placing a product 30 generally encompasses placing a product on at leastone pouch area of the second layer web.

Now referring to FIG. 9 and the steps of FIG. 8, in a variety ofembodiments multiple products 10 are placed on the second layer web incorresponding pouch areas 950 of the second layer web. The webs aresealed at step 40 to form a combined web 1000 by sealing the first layerweb to the second layer web at least at a first seal zone 930 so thatthe first layer is joined to the second layer by a peelable seal. Inmultiple embodiments, including the embodiment depicted in FIG. 9,forming a combined web also includes sealing the first layer web to thesecond layer web at a second seal zone 932 which is within a tab zone.The webs are generally sized to create multiple packages, and may bevery long, also referred to as continuous, in the machine direction andhave a cross-machine direction of one to five packages, or more.Combined web 1000 of FIG. 9 has a width of two packages, and is verylong in the machine direction. Very long in the machine direction isused to mean a web that is typically substantially longer than it iswide, such as one-hundred or one-thousand times longer than its width,and is often processed on rolls.

In at least one example implementation of the method of FIG. 8, sealingthe webs 40 is accomplished in line in a continuous motion machine. Aseal plate can be used for joining a first layer web and a second layerweb with a heat seal at a first seal zone 930 to form the combined web1000. In such an implementation the seal plate itself defines a firstseal zone having an inner perimeter and an outer perimeter, as well. Inthe web embodiment depicted in FIG. 9, such a seal plate would alsodefine a second seal zone 932 within individual package tab areas.

The combined web is then cut 50 to produce at least one individualpackage. The package is cut along center machine-direction cut lines910, cross-machine direction cut lines 920 and outer machine directioncut lines 925 to separate the individual package 900 from a matrix 936.The use of a matrix allows for some tolerance in the sealing and cuttingsteps.

In a variety of embodiments, the step of cutting 50 also includescutting only the first layer of the package at a tab cut location 940 todefine a tab zone in the package 900. As described above, the tab cutlocation is generally outside of the first seal zone 930 and is withinthe unsealed header area 922. In a variety of embodiments, eachindividual package is die cut around its respective outer perimeter andat a tab cut location. In at least one example implementation, the diecutting 50 is accomplished in a rotary die cutting station. In such anexample, the rotary die can cut against an anvil roll, for example. Inother embodiments, the packages are knife cut or guillotine cut at theirouter perimeters.

FIG. 10 is a schematic drawing of one embodiment of a package-makingequipment system 1010 that can be used to make packages as describedherein. The system 1010 includes equipment 1012 for providing the inputmaterials for the package, such as the first layer, second layer andproduct to be packaged. In one embodiment these materials are providedon rolls. A preliminary rotary die station 1014 may be provided in someembodiments before the heat seal station 1016 in order to perform anypreparatory cuts that are desired. In some embodiments, there is norotary die station 1014 before the heat seal station 1016, such as whereno preparatory cuts are needed.

The heat seal station 1016 performs the step of sealing the webs to jointhem together at the seal zones. In one embodiment, the heat sealstation includes multiple heat seal plates that are used to formdifferent seal zones. In one embodiment, a first seal plate is used toform a first seal zone, while a second seal plate is used to form asecond seal zone.

A rotary die station 1018 is provided where each package is cut alongits exterior perimeter, as discussed in relation to FIG. 9, to separatethe individual package from a matrix. Additional rotary die stations mayperform additional cuts, such as to cut the package in one layer at thetab cut location to form the tab zone. Alternatively, a single rotarydie station can perform both the exterior perimeter cuts and the tabzone cut through one layer. Output equipment 1020 is also provided forprocessing the individual packages made in the process. The schematic ofFIG. 10 shows basic equipment components, but it will be recognized byone of skill in the art that additional equipment could be provide otherprocessing functionality. It should also be noted that, as used in thisspecification and the appended claims, the phrase “configured” describesa system, apparatus, or other structure that is constructed orconfigured to perform a particular task or adopt a particularconfiguration. The phrase “configured” can be used interchangeably withother similar phrases such as “arranged,” “arranged and configured,”“constructed and arranged,” “constructed,” “manufactured and arranged,”and the like.

All publications and patent applications in this specification areindicative of the level of ordinary skill in the art to which thisinvention pertains. All publications and patent applications are hereinincorporated by reference to the same extent as if each individualpublication or patent application was specifically and individuallyindicated by reference.

This application is intended to cover adaptations or variations of thepresent subject matter. It is to be understood that the abovedescription is intended to be illustrative, and not restrictive.

We claim:
 1. A package for containing and dispensing a product,comprising: a first layer; a second layer; at least a first seal zonewhere the first layer is joined to the second layer by a peelable seal,the first seal zone having an inner perimeter that defines an unsealedpouch area for containing the product and an outer perimeter; and anunsealed header zone adjacent to the outer perimeter of the first sealzone, wherein the first layer is not joined to the second layer in theunsealed header zone; and a first tab cut in the first layer within theunsealed header zone, wherein the first tab cut divides the package intoa package zone and a first tab zone.
 2. The package of claim 1 whereinthe first layer is coextensive with the second layer so that the firstlayer and second layer share a common outer perimeter.
 3. The package ofclaim 1 wherein the unsealed header zone is positioned substantiallyalong one side of the package.
 4. The package of claim 1 furthercomprising a second seal zone where the first layer is joined to thesecond layer, wherein the second seal zone is within the first tab zone,wherein the second seal zone is separated from the first seal zone by aportion of the unsealed header zone.
 5. The package of claim 4, whereinthe first tab zone is located in a corner of the package, furthercomprising: a second tab cut in the first layer within the unsealedheader zone, wherein the second tab cut defines the boundary of a secondtab zone located in a corner of the package; and a third seal zone wherethe first layer is joined to the second layer, wherein the third sealzone is within the second tab zone.
 6. The package of claim 1 whereinthe package is substantially rectangular and wherein the unsealed headerzone is positioned substantially along one side of the package.
 7. Thepackage of claim 1 wherein there is no cut in the second layer at alocation corresponding to the first tab cut on the first layer.
 8. Thepackage of claim 1 wherein the product is a sheet product.
 9. Thepackage of claim 1 wherein the package is substantially rectangular andthe unsealed header zone is substantially rectangular and is locatedalong one side of the package, and wherein the first tab zone is definedat a corner of the package.
 10. The package of claim 1 wherein thepackage is substantially rectangular and the unsealed header zone issubstantially rectangular and is located along one side of the package,and wherein the first tab cut is curved.
 11. A method of forming apackage for containing and dispensing a product comprising: providing afirst layer web and a second layer web; placing a product on at leastone pouch area of one of the first and second layer webs; forming acombined web by sealing the first layer web to the second layer web atleast at a first seal zone so that the first layer is joined to thesecond layer by a peelable seal surrounding the at least one pouch area,and leaving an unsealed header zone adjacent to an outer perimeter ofthe first seal zone where the first layer web is not sealed to thesecond layer web; and cutting at least one individual package around anouter package perimeter to separate the individual package from thecombined web, wherein cutting further comprises cutting the first layerof the package at a first tab cut location within the unsealed headerzone to define a boundary of the first tab zone in the package.
 12. Themethod of claim 11 wherein forming a combined web further comprisessealing the first layer web to the second layer web at a second sealzone which is within the tab zone.
 13. The method of claim 11 whereincutting the individual package comprises die cutting.
 14. The method ofclaim 13 wherein cutting the individual package comprises rotary diecutting.
 15. The method of claim 11 further comprising forming a secondseal zone where the first layer is joined to the second layer, whereinthe second seal zone is within the first tab zone, wherein the secondseal zone is separated from the first seal zone by a portion of theunsealed header zone.
 16. The method of claim 11, wherein the first tabzone is located in a corner of the package, further comprising: cuttinga second tab cut in the first layer within the unsealed header zone,wherein the second tab cut defines the boundary of a second tab zonelocated in a corner of the package; and forming a third seal zone wherethe first layer is joined to the second layer, wherein the third sealzone is within the second tab zone.
 17. The method of claim 11 whereinthere is no cut in the second layer at a location corresponding to thefirst tab cut on the first layer.
 18. A device for forming a package forcontaining and dispensing a sheet product comprising: a heat seal platefor joining a first layer web and a second layer web with a heat seal atfirst seal zones to form a combined web, wherein the seal plate definesat least one first seal zone having an inner perimeter and an outerperimeter; and a cutting die for cutting the combined web to form atleast one individual package and for cutting through only the firstlayer at a tab cut location, where the first tab cut location is notwithin any of the first seal zones on the combined web.
 19. The deviceof claim 18 wherein the cutting die is a rotary cutting die.